GEMINI/WESTERBEKE OWNERS SEMINAR Introduction 1. Engines1 Personnel 2. Products Basic Engine Theory 1. Diesel Engines 2. Transmissions System Description/Checks 1 Fuel 2 Water, Fresh 3 Water, Raw 4 Exhaust 5 Electrical, DC 6 Getting Help Minor Repairs 1. Water Pumps 2. Filter Changes 3. V-Belt Changes 4. Oil Types 5. Tool List Scheduled Maintenance 1. Fluid Levels 2. Valve Adjustment 3. Cylinder Head Torque 4. Winterizing/Spring Commissioning Spare Parts 1. Emergency Spares 2.
ENGINES1 History Engines1 began its now 42-year venture as a sales/service support division of a local shipyard. The shipyard had a small yacht repair facility in Norfolk, VA that was in need of engines and parts to be competitive with engine repair. Over the years as the business grew and the products were taken to market at a distribution level it became clear that the 4 man department was more than just a support for the yard.
DIESEL ENGINE THEORY Diesel engines differ from other internal combustion engines in a number of ways. Compression ratios are higher than in spark-ignited engines. The charge taken into the combustion chamber through the intake consists of air only, with no fuel mixture. Injectors receive fuel under pressure from the fuel pump and deliver it into the combustion chambers at the right time in equal quantities and at the proper condition to burn.
POWER STROKE During the power stroke, the piston is pushed downward with both the intake and exhaust valves closed. By the time the piston reaches the end of the compression stroke, the burning fuel causes a further increase in the pressure above the piston. As more fuel is added and burns, the gases get hotter and expand more to push the piston downward and to add momentum to the crankshaft rotation.
MARINE TRANSMISSIONS Marine transmissions fall generally into two groups, mechanical shift or hydraulic shift. Mechanical transmissions connect the input from the engine to the output of the shaft by means of a mechanically operated assembly such as a dog clutch or shift fork that mechanically moves the gears into the selected position.
System Description/Checks Engine Systems Fuel On a diesel engine one of the most misunderstood systems is the fuel system. Consisting of two major and several minor parts the fuel system is generally the most neglected. When fuel leaves the tank it is pulled toward the engine by a primary fuel pump and then forced under pressure through the secondary filter to the injection pump. The injection pump pressurizes the fuel and sends it to the injector.
Fresh Water The engine’s fresh water system, also know as the closed cooling system consists of a circulating pump, heat exchanger, expansion tank, thermostat, and several hoses. This is the system that cools your engine. Water is pulled from the heat exchanger and pushed into the engine’s water jacket by the circulating pump. When the block and heads are full a tiny amount of water continues to circulate to help maintain a consistent temperature in the exhaust manifold and bleed air trapped in the system.
Raw Water The raw water system’s primary function is to cool the water used in the closed cooling system. The raw water system consists of a pump and a couple of hoses. Combined with a through hull fitting and strainer mounted off the engine. These are all that is involved. The raw water pump has a rubber impeller that is rotated in a housing. In this housing there is a cam that squeezes the rubber blades down and forces the water out of the pumps outlet through the hose, and into the heat exchanger.
This system check should include the hoses and clamps as before. Also check the muffler for cracks. If you have a rubber muffler check it for cracks and hardness of the rubber parts. Also check the exhaust elbow and the attaching clamp. Check the fitting at the hull and the clamps. One caution to always follow is not to over crank the engine. If the engine does not start in the normal cranking period turn the seawater valve to the off position.
Getting Help When preparing to make a call for service, following these simple guidelines will help the technician to better prepare with parts and any manuals, bulletins, or drawings needed to finish the job. This will save the tech time and you money. Check the Engines1 web site at www.engines1.com. The “Shoptalk” area has a lot of information about parts and service for your engine. Have your model and serial numbers handy and record your engine hours. When describing the problem be thorough.
Minor Repairs Water Pumps There are two water pumps on the engine. The pump that is mounted into the front of the block is the circulating pump. This pump is not rebuildable and must be replaced if a failure occurs. The second is the raw water pump mounted to the right hand side behind the timing gear case cover. This pump is driven by the timing gears and is a rubber impeller type.
Filter Changes Oil Filters: If there is one thing you should remember it is this: Your oil is the lifeblood of your engine. Cheap oil or old and dirty oil will lead to premature engine failure. Westerbeke has made changing the oil very simple. To change the oil start and run the engine for a few minutes to get it warm. This will help the oil to flow better. Locate the oil drain hose attached to the front area of the engine.
V-Belt Changes The V-belt on your engine turns the alternator and circulating water pump. Belts should be replaced when they show signs of cracking, shredding, stretching, or hardening. When replacing the belt all that is required is tension. There should be about ½” to ¾” deflection on the belt’s longest run from side to side. Installation Hints: Adjust tension as described above. Check all pulleys for cleanliness. Remove any rust or debris that will lead to premature failure.
Tool List: It is a good idea to carry enough tools on your vessel to handle most minor repairs while underway or general maintenance items at the dock. A simple list of tools that do not cost a great deal of money can save a lot of aggravation. Listed are the most common tools that you may need. Your list may vary depending on your comfort level with your repairs. Don’t be afraid to use your tools. Keep them stored in a dry place if possible or coat them with some spray lubricant for storage.
Scheduled Maintenance Fluid Levels: When checking the engine oil make sure the engine has been shut down long enough for the oil to drain into the pan. The dipstick is marked with a line to show full. Always make sure your oil is at this level. When checking the transmission oil is it a good idea to run the engine for a few seconds. Shut the engine down and check the oil. The transmission dipstick is also marked with a full line or ring on the dipstick. Always make sure the oil is at this level.
Winterizing/Spring Commissioning: Many owners rely on their boat yards to winterize their engines or generators for them, while some owners prefer to accomplish this task themselves. Below is a checklist of items to be performed on your engine or your generator for winter lay-up. Fresh Water Cooling System The use of a 50-50 solution of antifreeze and fresh water is recommended for use in the fresh water cooling system year round.
protect your raw water circuit from freezing during winter lay-up, as well as providing corrosion protection. Remove the impeller from your raw water pump (some antifreeze mixture will accompany it, so catch it in a bucket). Examine the impeller. Acquire a replacement if needed and a cover gasket. Do not reinstall the impeller back into the pump until the Spring commissioning. Intake Manifold With a clean cloth lightly soaked in oil, place it in the opening of the intake manifold so as to block it closed.
By following these few steps, you should afford your engine protection over the winter lay-up. This will also help familiarize you with the maintenance needs of your engine. If you have any questions regarding winter lay-up, call your local servicing distributor or Engines1, we will be more than willing to try and answer any of your questions. Spare Parts: The best way to deal with disaster is to be ready for it. Westerbeke offers several methods to help you keep spares on your vessel.
The other prepackaged kit offered is a hose kit. This kit provides all of the preformed hoses on your engine in a duffle bag. Cooling Hose Kit • • • • • Thermostat to Manifold Sea Water Pump to Exchanger Exchanger to Fresh Water Pump Manifold to Exchanger Hose Clamps General Spares: Attached is a list of common parts for the Westerbeke engine. This list was printed from the Engines1 web site. You will find several items of interest for your engine under the “Shoptalk” tab on the menu bar.
ENGINES1 CONTACT LIST To assist you in obtaining information from Engines1, we have listed below the name of key personnel, their direct telephone number, e-mail address and the subjects they should be contacted about. Division Manager Tim Walters 757-673-7209 Parts Manager Cal Cooper 757-673-7201 Parts, engine, generator sales, return goods authorization Parts Sales Jack Bowe 757-673-7204 tim@engines1.com cal@engines1.com jack@engines1.
